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Powerful Performance
Powerful
Performance
At Home in Energy Plant Engineering

From Coal to Electricity
Generation of electricity in a typical coal power plant
Before being injected into the furnace, the raw coal is crushed down to a fine pulverized form in the coal mills.
Flue gases up to 1,450 °C arise from pulverized fuel combustion in the steam generator furnace. The liberated heat
is used to generate high-pressure and high-temperature steam.
The steam is directed to a turbine; it flows onto the blade wheels and turns the turbine shaft. An attached generator
then generates the electrical power.
With the help of catalysts, the nitrogen oxides in the flue gas react in the DeNO x system to produce nitrogen and
water vapor.
Ash particles adhere to electrically-charged surfaces in the electrostatic precipitator; they are rapped and removed
from the flue gas.
In the flue gas desulphurization system (FGD) lime slurry or suspended pulverized limestone bind the sulphur dioxide
coming from the flue gas. The final product arising is gypsum.
2

Contents
Energized
As an energy plant constructor with a
long track record, Hitachi Power Europe
benefits from the boom in power plant
engineering.
from page 4
!
Click on the section
to get there directly
Our Staff
From engineers to technicians:
our emphasis is very much on
team work.
from page 10
Our Projects
Whether at home or internationally,
we build power plants and supply
components to many regions.
from page 16
Our Products
Whether it be pressure parts,
firing technology or steel structures,
we have our own manufacturing
facilities for them.
from page 26
Our Know-How
New materials and CO 2 capture
form the basis for tomorrow’s
power plant.
from page 36
At Home in Energy Plant Engineering 3

Energized
With a track record going back over 100 years, energy plant
constructor Hitachi Power Europe GmbH benefits from
the rising demand for electricity and the worldwide boom
in power plant engineering.
En

ergized
Hitachi Power Office, Duisburg

Hitachi Power Europe
Some 900 people
work in the offices at the
Duisburg Inner Port
Stakeholders in
Hitachi Power Europe GmbH
HPE
60% Hitachi, Ltd.
26% Hitachi Europe Ltd.
14% Babcock-Hitachi K.K.
A track record going back over 100 years in the power plant field, efficient products,
a highly motivated workforce and a parent company of real strength and substance: that
is Hitachi Power Europe GmbH (HPE). The energy plant constructor both designs and
builds fossil-fired power plants and – through its references – ranks as one of the market
and technology leaders. HPE also supplies key components, such as utility steam
generators, environmental engineering equipment, turbines and pulverizers.
Hitachi Power Europe’s history goes back to 1898 and the establishment of “Deutsche
Babcock & Wilcox Dampfkesselwerke AG” in Berlin. In 2003 Babcock-Hitachi K.K.,
a subsidiary of Hitachi, Ltd., acquired the power engineering field and the entire knowhow
in steam generation and combined-cycle power plants of the former Babcock
Borsig Group, Oberhausen. Following complete takeover by the Hitachi Group,
the company was renamed Hitachi Power Europe GmbH in 2006.
In 2007 the energy plant constructor set up its head offices at the Inner Port of Duisburg /
North Rhine-Westphalia. Including subsidiaries, approx. 2,000 staff are on the company’s
payroll (As of: May 2013).
Along with power plant engineering and supplying key components, the plant constructor
also concerns itself with forward-looking services. Green technologies – in energy
storage and biomass, for instance – are examples of Hitachi Power Europe innovation
and reliability.
6

Internationally on the Go
Hitachi Power Europe GmbH (HPE) is one of the three Hitachi subsidiaries in energy
plant engineering. With Hitachi Power Systems (headquartered in Tokyo) and Hitachi
Power Systems America (New Jersey) dealing with the Asian and American power plant
markets respectively, HPE is responsible within the Group for the markets in Europe,
Africa, Russia (incl. Belarus) and India. At the same time, HPE supports the global
capital expenditure schemes of the electricity generators in Europe. HPE is the Center
of Competence within the worldwide operating Hitachi Group for the electrification of
lignite / anthracite.
SUBSIDIARIES AND RELATED COMPANIES OF HITACHI POWER EUROPE
1 Hitachi Power
Europe GmbH
1 2
6
4
7
2 Babcock
Fertigungszentrum
GmbH
3 BGR Boilers
Private Ltd.
4 Donges
SteelTec
GmbH
5 Hitachi
Power Africa
(Pty) Ltd.
6 Hitachi Power
Europe Service
GmbH
7 Meeraner
Dampfkesselbau
GmbH
3
5
Energized 7

Development Costs Energy
Given rising populations, a growing economy and new products – no development is
possible without energy. And it is principally electrical energy – that is power – which
is needed for the production and transportation of merchandise, products and services.
Competitive economic systems rely on a healthy mixture of various fuels and a raised
level of energy efficiency. Most of the electricity is generated in the world by fossil
fuel-fired power plants – after all, they are tried-and-tested, reliable under continuous
operations and economical to run. In particular, the latest generation of coal, lignite and
gas-fired power plants ensure that environmental pollution is kept well down. An added
plus: fossil fuels, such as coal and lignite, are available for supply in many politically and
socially stable countries and their reserves will last for literally hundreds of years.
DEVELOPMENT OF COAL CONSUMPTION (in million tons)
3,646
World 5,522
China
1,317
2,543
India
279
504
OECD*
1,451
1,735
1995 2007 *30 primarily Western industrial countries
Source: IEA, estimated figures for 2007
Currently, the world has a population of approx. 6.8 billion people. The world’s population
has doubled within the last 50 years and will continue to increase. Moreover, a
quarter of mankind is still without electricity. For this very reason electricity consumption
is set to rise more rapidly than all the other forms of energy consumption. Experts expect
a doubling of electricity requirements by 2030. Hence, the challenge facing companies,
the political world and society in general is quite clear: everything must be done to
ensure that energy is generated sustainably, reliably and economically.
THE SHARE OF COAL IN THE GENERATION OF ELECTRICITY (%)
Poland
Australia
China
India
Czech Republic
USA
50
Germany 47
59
69
80
78*
93
Source: IEA, all figures for 2006 except * for 2005
8

Tops in Power Plant Construction
It is no surprise on account of its long tradition, ultra up-to-date products and immense
know-how that Germany is one of the top countries for the construction of energy plants.
This is very much down to the world’s highest efficiencies for fossil-fired power plants,
tough environmental protection provisions and the leading role taken in researching and
developing new, more productive materials and CO 2 capturing technologies.
The demand for both new and replacement plants is considerable given the global rise
in electricity consumption and the fact that many power plants will be reaching the end
of their service lives over the next few years. It thus comes as no surprise to find
that the power plant industry is booming. In the EU countries alone – with approx.
752,000 megawatts (MW) of installed electricity generating capacity – it is expected that
300,000 MW will have to be replaced by 2020.
The major plant construction business in Germany (power plants, iron & steel works
and rolling mills, electrical equipment, cement units) is also a major export factor as
shown by the fact that some 80 % of the orders come from the international markets.
All these factors will continue to bring about an increase in the demand for products and
know-how from the energy plant engineering / power plant sectors.
TOTAL ORDER INTAKE BY REGIONS (2012)
The boom in major plant
construction is principally
down to orders from abroad
Industrial
countries 16.2%
Germany 19.0%
Rest
of the world 20.5%
Asian /
23.8% Pacific Region
Eastern Europe
11.6% and CIS
8.8% Middle East
Source: Arbeitsgemeinschaft Großanlagenbau in the VDMA
TOTAL ORDER INTAKE IN MAJOR PLANT CONSTRUCTION 1970 to 2012 (in EUR billion)
35
Total
30
25
20
15
10
5
Abroad
Germany
0
2012
2010
2008
2006
2004
2002
2000
1998
1996
1994
1992
1990
1988
1986
1984
1982
1980
1978
1976
1974
1972
1970
Source: Arbeitsgemeinschaft Großanlagenbau in the VDMA
Energized 9

Our

Staff
Our Staff
From the engineer to the commercial employee, from the
technician to the project assistant: emphasis is very much
on team work at Hitachi Power Europe.

Designing with Ultra Modern Software
Special IT tools image
power plants and components
both virtually and in 3D
Energy plant constructor Hitachi Power Europe specializes in power generation in highlyefficient
coal and lignite-fired plants. In addition, turnkey gas and steam power plants
tailored to customer requirements form part of its work & services.
Whether it is a utility steam generator, turbine, coal mill or environmental engineering,
each and every power plant consists of numerous components which must be operated
productively, reliably, economically and in an environmentally compatible manner.
In design work, HPE makes use of the most up-to-date IT tools for optimum plant
planning. These tools – 3D CAD software and virtual reality solutions, for instance –
are vital in optimizing plant arrangement and calculating flows in a utility steam generator
furnace. This makes it possible, amongst other things, to raise in advance the service
lives of system parts and thus save on costs.
Hitachi Power Europe both uses and refines design software for the construction and
commissioning of power plants and components. It should, in future, be possible to
image a complete power plant virtually on the computer – inclusive of all the ongoing
data and readings. A number of benefits would arise from this “dynamic simulation” of
an overall plant. One of them would be to train staff for their tasks and another would
allow simulation of vital processes – starting up a power plant, for instance, following an
inspection – at the computer.
12

Our Own Installation Teams on Site
Hitachi Power Europe has an extensive track record going back over many years in
energy plant engineering both in Germany and abroad. Our installation teams concern
themselves not only with planning / design and engineering but also with monitoring work
at the project sites, controlling logistics and personnel needs, carrying out continuous
controlling and ensuring there is no trouble in placing components into service.
Hitachi Power Europe not only supplies its own components and replacement parts
for coal mills and burner technology, for instance, but also undertakes plant servicing.
The competence and know-how needed for power plant component maintenance and
upkeep is bundled in our own service division.
Experienced Hitachi Power
Europe staff supervise
power plant construction
Our Staff 13

Looking for Traces
Samples are analyzed both under
a scanning electron microscope and
in the chemistry laboratory
The scanning electron microscope sheds light on the matter – even the most minute
traces become clearly visible when magnified 100,000 times. This is a factor of real
significance when the fractured surfaces of materials, for instance, are examined. But
this is only one of a number of tasks which the staff in the Hitachi Power Europe
laboratory concern themselves with on a daily basis.
The experts in material technology and chemical analysis make use of the most
up-to-date equipment. They examine and analyze fossil fuels, determine, for example,
the calorific value and grindability of various coal types and look for trace elements
in combustion residues (in slag and ashes, for instance). Their aim is to both improve
combustion and, at the same time, cut back on environmental pollution. This can be
achieved, for example, by optimizing the design of coal mills and burners for the various
fuel types.
Specialists carry out damage analyses and remaining service life investigations –
something involving the examination of hundreds of material specimens every year.
They check on processability and ensure that any newly developed materials are suitable
for future power plant generations. That is why close collaboration with those involved
in projects / design work and with commissioning engineers is something quite natural
for the laboratory’s staff. The Hitachi Power Europe laboratory is accredited in keeping
with DIN EN ISO / IEC 17025.
14

Motivated Employees
Fresh trainees get to know –
accompanied by company
representatives – the various
departments; including the
HPE laboratory
Exceptionally well trained employees working independently at a knowledge level – this
is where the success of any company can be found. Here Hitachi Power Europe provides
the best-possible prerequisites for both those starting off in the company (trainees,
student trainees, university graduates) and for our long-standing colleagues.
The company is popular as an employer – particularly with young people. As a result,
around 50 young people apply, on average, for each training post. Standing as
confirmation for the high-quality of the training is the fact that practically all trainees
are allowed to prematurely take their final examinations in view of their good grades.
Hitachi Power Europe also sustainably invests in further / ongoing training for company
employees in response to requirements. For both company employees and management,
specific, Group-wide training steps provide a wide range to choose from.
The international scope of HPE as an energy plant constructor – with projects extending
from Europe to South Africa and India – widens the personal and professional horizons
of our staff. Thanks to international assignments, they get to know different approaches
to work and thus make use of their full potential. After all, the basis for constant
innovations can only be accomplished by motivated and qualified staff.
Training also includes
visiting a power plant site
Our Staff 15

Our Projects
Whether it is in Germany, Europe or in the rest of the
world, we build power plants and supply components
to many regions.
Our P

ojects
Bituminous coal plant – Maasvlakte / Netherlands

Specialist for the Power Train
The “Power Train” comprises the
major components of a power plant
The three components utility steam generator, flue gas cleaning equipment and turbine /
generator (including their balance-of-plant equipment) form the “Power Train” of a power
plant. Energy plant constructor Hitachi Power Europe specializes in designing, construct
ing and commissioning such power trains.
HPE has an extensive track record in unit sizes to over 1,000 MWel in conventional
power plants (coal, gas and oil-fired boilers complete with steam turbines). The focus
in combined-cycle power plants (gas / steam turbine power plants) is in the 40 MW to
400 MW (800 MW) capacity range.
Our specialists’ know-how extends across all the steps needed for designing and
construction including:
Approval planning
(preparing approval applications, consultations with public authorities)
Concept-making
(incl. feasibility calculation, benchmarking, cycle operation simulation)
Basic and detail engineering
(from process engineering through to electrical engineering, instrumentation &
control and plant layout)
Project management (scheduling, expediting, cost tracking, quality assurance)
Purchase support
18

›› 45 %+ Degree of Efficiency
Whether it involves power plants, the power train or utility steam generators – Hitachi
Power Europe has the required experience and know-how to meet customer-specific
requirements in power plant engineering. As a fully fledged energy plant constructor, the
company is in a position to supply individual components and also to plan, erect and
start up complete plants. Since 2007, Hitachi Power Europe has placed over 20,000 MW
of installed capacity either into service or is engaged in its construction.
An example here is the Moorburg coal power plant with HPE constructing the two utility
steam generators for the double-unit system for customer Vattenfall in the port of
Hamburg. On completion, the power plant will have a 45 %+ efficiency and then be one
of the most modern of its kind in the world. The high net efficiency provides not only a
considerably greater output but also saves on resources (less fuel used) compared to
power plants to date and reduces the specific CO 2 emissions.
Specifications of Moorburg Units A / B
Power output
Fuel
Live steam
parameters
2 x 820 MW
bituminous coal
600 °C / 305 bar
Net efficiency over 45 %
Boiler house height 100 meters
Total weight
pressurized part per unit 3,900 t
Project Moorburg
Our Projects 19

At Home in Lignite …
It is not only coal power plants but also lignite-fired ones which can guarantee an
assured supply of electricity around the clock. Over the past few years various energy
suppliers have either started to modernize their lignite power plants or to rebuild them.
On account of its many years of experience with this fuel, Hitachi Power Europe has
established itself as a supplier of the latest generation of highly efficient utility steam
generators for these projects.
For example: the two new RWE Power AG power plant units (total 2,240 megawatts
capacity) at the Neurath site. This is where Hitachi Power Europe, as consortium leader,
is erecting two utility steam generators with an efficiency up to 43 % – a peak figure
worldwide. The two units represent the latest stage reached in steam generator
technology across the world. They feature supercritical steam pressures and the highest
steam temperatures ever realized for lignite.
Hitachi Power Europe has also erected an ultra-modern utility steam generator for a new
lignite power plant unit at Boxberg in Saxony and placed it into operation. Just like other
customers, Vattenfall relies on the large lignite reserves which make it possible for lignite
power plants to be built and operated. Thanks to the much greater degrees of efficiency,
the new plants emit much less CO 2 than today’s power plants. At the same time, the
plants conserve valuable resources since less fuel is needed for the same quantity of
electricity.
A further benefit is that Hitachi Power Europe has its own firing technology components
which are optimally adapted to the particular requirements of the various lignite types
(e. g. circular jet burners).
Example – Boxberg:
efficient utility steam generator
in the lignite power plant
20

… and with Gas-Fired Plants
Short reaction times and particularly high degrees of efficiency – both the principles
of a gas turbine and steam power plant are united in a combined-cycle power plant.
The fact that these extremely efficient plants have both a gas turbine and a (downstream)
steam turbine ensures that degrees of efficiency up to 60 % are reached.
Combined-cycle power plants
as in Malmö come up with peak
degree of efficiency figures
In gas-fired plants as well, Hitachi Power Europe has an extensive know-how and
a track record going back over many years across the whole spectrum from design,
acquisition and construction through to commissioning. The highly successful and
globally deployed H-25 / H-15 gas turbines – as well as the newly developed H-80 gas
turbine – from the parent company Hitachi, Ltd. are just right for a reliable, efficient and
economical operation of the power plants. The HPE engineers are also highly familiar
with the large 400 MW combined-cycle plants. General contractor Hitachi Power Europe
erected a combined-cycle power plant with integrated district heating supply in the
Southern Swedish port of Malmö. This combined operation is responsible for up to 89 %
of the gas energy being utilized.
In this project Hitachi Power Europe staff were responsible for the overall plant
layout, constructional planning / implementation, installation and commissioning.
During construction, the engineers surmounted considerable challenges – such
as integrating the plant into the building of a former coal power plant and the groundwater
level. The power plant is the replacement for the existing Scandinavian
coal-fired plants and will see carbon dioxide emissions going down every year by around
1 million tons.
Our Projects 21

Highly Efficient Boilers
Two examples of highly efficient
utility steam generators from
Hitachi Power Europe: Neurath (top)
and Datteln (bottom)
Thousands of welds, hundreds of miles of pipes, several ten thousand tons of steel
structures: the heart of every fossil-fired power plant is the utility steam generator (boiler).
This is where the pulverized fuel is combusted at approx. 1,450 °C and where the hot
flue gases and very hot steam under extremely high pressure (subsequently driving the
turbine blades) arise.
With a track record going back over 100 years, Hitachi Power Europe is one of the
market and technology leaders in utility steam generators. Our references are made up
of over 370,000 megawatts of power plant capacity (180,000 MW in coal firing,
43,000 MW in lignite firing and 140,000 MW in oil and gas firing) installed since 1970.
HPE develops, constructs and supplies steam generators for over 1,100 MWel unit
outputs involving 300 bar+ pressures, 600 °C live steam temperatures and reheater
temperatures up to 620 °C for all available fossil fuels. These range from coal / lignite to
problematical fuels (e. g. gases from coke ovens / steel works, refinery residues).
Utility steam generators are being constantly refined for operation – with the use, for
instance, of new highly resistant materials – under even higher steam temperatures and
pressure. In this way, the degree of efficiency of tomorrow’s coal-fired power plants
can be raised to over 50 %.
22

Wide Range of Fuels
Whether as pulverizers, burner or deashers, a large number of components are in use
in and around the utility steam generator. Hitachi Power Europe firing systems and
components cover a wide range of gaseous, liquid and solid fuels. The corresponding
equipment is optimized for both coal and lignite pulverized firing systems. As a designer
and manufacturer of original parts, the company is also an ideal partner for modernization
work and replacement part needs.
Solid Fuel Firing Systems
and Components
More information
in our brochure
Depending on selection criteria (e. g. fuel property, emission standards, ash recycling),
HPE provides the optimum firing systems for bituminous coal and lignite. For instance,
the HPE-developed burner generation with its numerous patents features minimum
emissions and maximum flexibility.
The coal mill feeders in the form of conveying equipment (drag chain and belt conveyors)
and steel plate conveyor feeders developed by Hitachi Power Europe are also designed
for top, fail-safe performances. Pulverizers (for grinding and drying bituminous coal and
lignite) have been part of the scope of production and services of Hitachi Power Europe
for many years now.
Our trade references with burners for gas /oil fired plants or alternative fuels (e. g. blast
furnace gases and refinery residues) are based on a lengthy track record on the
commercial scale.
from l. to r.:
DS ® Burner, RS ® Burner
and DST Burner
To film gallery
on our home page
MPS ® Mills
Our Projects 23

›› Electrical Power for South Africa and India
Six utility steam generators
for each of the Medupi and
Kusile sites are to be delivered
(right: Medupi, March 2012)
1 Medupi
2 Kusile
3 Johannesburg
1
3 2
3
1 Meja
2 Raghunathpur
3 Solapur
4 Chennai
1
2
4
End 2007 / start 2008, South African energy supplier ESKOM ordered 12 coal-fired utility
steam generators each with a capacity of 800 MW. Hitachi Power Europe and Hitachi
Power Africa (Pty) Ltd. (HPA) – our South African subsidiary – are constructing the
key components at both the Medupi and Kusile power plant sites. This major order
is of an approx. EUR 4bn volume with the scope of delivery comprising design
engineering, acquisition, erection and commissioning. The utility steam generators will
be going on stream as from 2013. Once in operation, the utility steam generators
will rank amongst the most up-to-date in South Africa. In addition, they will have a
significantly improved efficiency over existing plants. Hitachi Power Europe’s
commitment in South Africa is of a long-term nature. Many of the components will be
designed and manufactured on the spot; in fact, 60% of the order volume will remain in
the country as local value added.
India is one of the world’s most rapidly growing markets for energy plant constructors.
The total capacity installed on the Indian sub-continent is set to more than double to
approx. 330,000 megawatts (MW) between 2010 and 2017; currently some two-thirds
of the power is generated in fossil-fired power plants. Hitachi Power Europe’s first step
on this rapidly expanding Indian market turned out successfully in 2012. Together with
a joint venture partner, HPE secured the order to supply six 660 MW bituminous coal
utility steam generators. The joint venture (“BGR Boilers Private Limited” based in
Chennai) was set up in 2010 by Hitachi Power Europe and Indian plant constructor BGR
Energy Systems Ltd. to manufacture and market super-critical utility steam generators
on the spot and place them into operation. BGR Energy and HPE parent Hitachi, Ltd.
had also signed up to another joint venture for manufacturing steam turbines (“BGR
Turbines Company Private Limited“). Thus HPE, Hitachi and BGR are in a position to
operate as a fully-fledged EPC contractor on the Indian market and supply all the major
components for power plant construction.
24

›› Polish and Greek Markets Entered
In September 2012, Hitachi Power Europe and consortium partner Polimex-Mostostal
(PXM) signed the contract with Polish energy supplier Enea Wytwarzanie for construction
of the Kozienice 11 bituminous coal plant. The value of the order for the 1,075 MW plant
(net efficiency: 45.5 %) is EUR 1.54bn. HPE’s scope of supply comprises the utility
steam generator including coal bunkers, mills, firing system, flue gas cleaning equipment,
the overriding instrumentation & control and a number of ancillary facilities. Parent
Hitachi, Ltd. is supplying the steam turbine and related components. HPE sister
company Babcock-Hitachi K.K. (BHK) – as subcontractor – is seeing to the matter of
flue gas desulphurization. PXM is responsible for the construction part, erection work
and much of the balance-of-plant. Up to 2,500 people will be working on the site during
the construction period and a significant share of the value added will remain in Poland.
The new unit will start commercial operations in 2017.
Hitachi Power Europe and customer TERNA S.A. are to construct an ultra-modern
lignite power plant with a 660 MW installed capacity in northern Greece. Greek energy
supplier PPC (Public Power Corporation) signed the contract with plant constructor
TERNA in March 2013. As TERNA’s sub-contractor, HPE is responsible for the design
engineering, supplying the utility steam generator including balance-of-plant and
together with parent Hitachi, Ltd. the steam turbine and the complete flue gas cleaning
system. TERNA will construct and place into operation both the power plant and its
balance-of-plant. Building is due to start for “Ptolemais V” in 2015; it will assume
commercial operations in 2019.
Bituminous coal plant –
Kozienice 11
Lignite coal plant –
Ptolemais V
Our Projects 25

Our Products
Our own manufacturing facilities providing boiler
pressure parts, firing technologies and steel structures make
us largely self-sufficient in power plant engineering.
Our Pr

oductsDonges SteelTec GmbH

Greater Autonomy Thanks to …
Coal mills and burners are built in
the Babcock Manufacturing Center
in Oberhausen (top, below right)
In contrast to most other power plant companies, Hitachi Power Europe GmbH has its
own manufacturing facilities for the major components. These include pressure parts
for utility steam generators, headers, coal mills and burners, material handling systems
and steel structures. This means that HPE is not primarily tied to sub-contractors and
creates a true “Alliance for Quality”. An overview of the three manufacturing facilities:
Donges SteelTec GmbH (Darmstadt): one of the leading German steel and bridge
construction companies; manufactures steel structures in the power plant field
Meeraner Dampfkesselbau GmbH (Meerane): manufactures complex components
for utility steam generators (pressure parts, for instance) for power plants
Babcock Fertigungszentrum GmbH (Oberhausen): manufactures high-grade
components (e. g. coal mills, coal burners, material handling systems) principally
for Hitachi Power Europe GmbH
Included in Meeraner
Dampfkesselbau GmbH’s
supplies are pressure parts
and headers (left)
28

… Our Own Production
Donges SteelTec GmbH
manufactures steel structures
for power plants
Maximum quality is needed in power plant engineering particularly since components are
subject to considerable stresses and must dependably perform their functions for
decades under continuous operations. That is why our subsidiaries have established
special priorities in controlling production quality.
Thanks to constant refinements in high-tech materials involving, for instance, special
alloys for pressure parts, components can be used ever more economically and in a
more environmentally compatible manner. At the same time, Hitachi Power Europe
specialists work closely together with their colleagues in the production facilities.
Power plant projects abroad – such as in South Africa or in India – often require a large
proportion of the components to be constructed and made locally. To this end, Hitachi
Power Europe enters into local cooperation schemes, constructs manufacturing facilities
and qualifies the local workforce for the project.
The company is also at the
cutting edge of matters in general
bridge and steel construction
Our Products 29

A Clean Aspect
Whether it is a matter of coal dust collection, desulphurization or denitrification, much
of the capital expenditure in building modern power plants goes into environmental
engineering. After all, flue gases containing ash particles, nitrogen oxides and sulphur
dioxides form during coal combustion. Highly effective processes can cut back these
emissions to the greatest possible extent. Modern technology is responsible, for
instance, for 99.9 % of the dusts being discharged from the flue gas. Other processes
ensure that few emissions arise from the other constituents:
Air Quality Control Systems
and Components
More information
in our brochure
Ash particles adhere to electrically-charged plates in the electrostatic precipitator;
they are rapped and removed from the flue gas.
Nitrogen oxides (NO x ) react with ammonia and with the aid of catalysts are
converted in the DeNO x system to nitrogen and water vapor – the natural
constituents, in fact, of air.
Sulphur dioxide can be filtered out in the flue gas desulphurization system (FGD).
Lime slurry binds it in the flue gas and the final product is pure gypsum.
Hitachi Power Europe has extensive knowledge available and a long track record in flue
gas cleaning. The company can deliver the components turnkey, if needed. In addition,
HPE and parent company Hitachi, Ltd. are constantly researching into new processes
to raise flue gas cleaning system efficiencies.
The FGD filters sulphur
dioxide out of the flue gas
30

Still Dependable under High Stresses
Faster than sound: the blade tips of a turbine rotate approx. 3,000 times a minute. Even
though subject to extreme stresses from the extremely hot (up to 620 °C) steam under
very high pressure (up to 250 bar), the blades they still have to dependably function
around the clock.
Highly efficient steam turbines are
supplied by Hitachi, Ltd., our parent
company
A new Hitachi development:
the H-80 gas turbine
For over 75 years now Hitachi, Ltd. has been supplying highly efficient 250 to
1,380 megawatt (MW) steam turbines. The turbines and generators are manufactured in
the Japanese Hitachi Works northeast of Tokyo. Comprehensive research, refinements,
improved design and manufacturing technology ensure that they belong to some of the
best of their type in the world.
Tough quality checks are carried out by Hitachi engineering teams to ensure maximum
performance and quality. These teams also provide continuous and extensive support
for customers and also service and modernize the systems.
Another success story comes in the form of the H‐25 / H‐15 gas turbine developed
by Hitachi, Ltd. Designed as a heavy duty machine (30 MW rating class), over 150 gas
turbines of the H-25 / H-15 type are in service throughput the world in power plants.
The H-80 newly developed gas turbine from Hitachi has also been in use for power
production purposes since the beginning of 2010.
The gas turbines are sound and reliable under continuous operations, require little
maintenance outlay and are admirably suited for cogeneration / district heating supply
plants. Hitachi gas turbines are also used as drive turbines in industry (e. g. mineral oil
business).
Our Products 31

Hitachi Power Europe Service GmbH
Hitachi Power Europe Service ist ein
eigen ständiges Unternehmen der Hitachi
Gruppe und bündelt die Service aktivitäten
der Hitachi Power Europe GmbH.
Hitachi Power Europe Service is an
independent subsidiary of Hitachi Group
and bundles the service activities of
Hitachi Power Europe GmbH.
Our Service …
Energie nach Maß
Energy Made to Measure
More information
in our brochure
Supplying spare parts, upgrading components, raising efficiencies and extending
service lives: Hitachi Power Europe Service GmbH (HPES) – an HPE subsidiary as from
1 August 2012 – provides comprehensive solutions for fossil-fired power plants and its
centerpiece steam generator.
HPES is an internationally operating company in energy generation and plant service.
Its divisions comprising Boiler & Firing Technology, Flue Gas Cleaning, Mills & Turbine
Service, Erection Work, Startup and Spare Parts Management ensure that fully
developed services are available to upgrade power plant and firing systems of various
designs and sizes for all conventional fuels.
Evaporator module erection for a
waste-to-energy (WTE) incinerator
32

… for Tomorrow’s Energy
Manufacture of components for
initial equipping, modification and
spare parts
More exacting requirements placed on emission control protect the environment. HPES
supplies fully developed and proven cleaning equipment – such as electrostatic
precipitator, fabric filter, scrubber and spray absorber – with which to comprehensively
comply with these requirements.
Patented protective coatings of heating surfaces and pressurized system components
ensure long service lives under corrosive and erosive conditions.
Whether lignite or bituminous coal, internal or external products are involved, HPES has
an extensive know-how on coal mill optimization. Its portfolio is rounded off with spare
parts, repairs and a comprehensive on-the-spot service.
Turbine service is carried out under the premise of “Maintaining output and availability”.
HPES specialists can resort to the lengthy track record in the construction, startup and
service of steam and gas turbines within the Hitachi Group.
As a 100 % subsidiary of HPE, HPES is in a position to access the manufacturing
facilities both within the HPE Group and of associated partners. Spare Parts Management
makes possible both rapid reactions and dependable solutions.
Our Products 33

Hitachi Power Europe Service GmbH
Hitachi Power Europe Service ist ein
eigen ständiges Unternehmen der Hitachi
Gruppe und bündelt die Service aktivitäten
der Hitachi Power Europe GmbH.
Hitachi Power Europe Service is an
independent subsidiary of Hitachi Group
and bundles the service activities of
Hitachi Power Europe GmbH.
›› Extremely Resilient
The “Shield for Accelerated
Boiler Service” in use in Unit Q
of the Boxberg power plant
SABS ® Sicherheits abschottung
SABS ® Shield for Accelerated Boiler Service
More information
in our brochure
The material is incredibly thin yet extremely tear-resistant. Being referred to here is the
several tons which a fabric devised by Hitachi Power Europe for inspection of utility
steam generators can withstand. The “Shield for Accelerated Boiler Service” (SABS ® )
protects workers engaged, for instance, in inspection work or working on a fault inside
a boiler from any falling slag lumps.
The patented and TÜV-certified SABS ® system consists of a fabric coated with Kevlar
and extends across the entire cross-section of the utility steam generator.
It is mounted and moved on a support structure also developed by Hitachi Power
Europe. In contrast to conventional solutions (scaffolding fitted along the boiler walls;
tensioned safety nets), SABS ® provides not only more dependable protection but is also
quicker to assemble and dismantle. It thus saves on both time and costs.
Following exhaustive tests, SABS ® was effectively deployed for the first time in the
inspection of Unit Q at the Boxberg power plant in mid-2012. Fabric spanning in the
boiler took only 6 ½ hours. During unit cleaning, it intercepted up to three tons of material
several times.
HPE devised both
the SABS ® fabric and the
support structure.
34

More Flexibility
1 Indirect firing
DST Burner
Cyclone
Coal
Dust
Bunker
Air
Raw Coal
Bunker
40 %
30
20
10
0
Minimum Load
1
3
5
12 %
10
8
6
4
Ramp Rate
5
2
1
2 Reduced wall thickness
and increase in number of
separators / headers
3 DST Burner
4 100 % biomass capable
5 GT repowering
100% Biomass
Capable
Conveying
Classifier
Feeder
Power Output
+30 Δ%
+20
5
Plant Efficiency
+3Δ%
5
+2
CO2 Emissions
0 Δ%
4
–10
G
Fan
Mill
+10
0
+1
0
–20
5
–30
An appropriate configuration of existing technologies will not only significantly increase
flexibility of a coal-fired power plant (also one that is optionally biomass-fueled) but also
contribute – from cost savings – to greater plant competitiveness. The above scheme
shows how to retrofit a conventional fossil-fueled power plant into a hybrid-fueled, high
load and operationally flexible power plant – one which assures a maximum utilization
of renewable sources and production of additionally combined heat and power.
To film gallery
on our home page
By upgrading the firing system with an indirect firing capability 1 it is possible to reduce
the minimum firing rate by approx. 15 %, if permitted by the burner control range. In
conjunction with a retrofit utilizing DST Burners 3 the minimum firing rate can be
lowered to about 10 % thanks to the burners’ wide control range. Below 10 % electrical
power can be generated by using a connected gas turbine, as in the case of gas turbine
repowering 5. Implementing an indirect firing system makes it possible to reach the
designed ramp rates of newly build or older boilers; a reduction of thickness of thick
walled components 2 clears the way for reaching a possible ramp rate of up to
10 % / min. Further ramp rate improvements come from gas turbine repower ing 5.
Thus repowering / topping – using gas turbines either in combined mode or recovery
preheating – makes it possible to improve flexibility by combining two different
generation types in a smart way. It also enables the gross power output to be increased,
plant efficiency enhanced and CO 2 emissions cut. The latter can also be achieved
by using an indirect firing system 1 combined with DST Burners 3 burning (e. g.)
woody biomass 4.
Operation Improvements
Up to 90 % of costly support fuel can be saved by switching very quickly to
minimum stable coal / biomass load during start up.
Mill operation for the indirect firing system – preferable during off-peak times –
enhances efficiency due to constant mill speed in the optimum energetic range.
Reducing auxiliary power consumption by introducing frequency speed control
to induced and forced draught fans additionally elevates part load efficiency.
Our Products 35

Our Know-How
Whether it is new materials or CO 2 capturing technologies –
our experts are today researching into and developing the
next generation of power plants.
Our Kno

w-How

New Materials, Greater Efficiencies
From CO 2 capture and new materials through to computer power plant simulations,
Hitachi Power Europe is researching into and developing new technologies for future
power plant generations. To this end, as a plant constructor and specialist for fossil
fuel-fired power plants, the company can look back on its extensive expertise and on a
host of references. One of the research projects involves HPE experts in developing
new, highly resistant nickel-based alloy pressure parts for the “700 °C power plant”.
Maximum precision for best
quality: production in Meerane is
already prepared for the
“700 °C power plant” materials
The usual power plants, for instance coal-fired ones, operate at 500 °C and approx.
240 bar. One of the ways to raise the degree of efficiency of the overall plant is
to increase the temperature and pressure to 700 °C and 350 bar respectively. This
would allow a 50 %+ degree of efficiency to be attained (as against the 38 % German
average).
Since normal power plant steel can only withstand temperatures of around 600 °C,
completely new materials are needed for this “700 °C power plant”. That is why Hitachi
Power Europe – in collaboration with a power plant operator – is researching into special
steel alloys with high nickel and chrome proportions. These alloys make the material very
resistant to high temperatures and pressures.
In cooperation with a power plant operator, Hitachi Power Europe has – through its
subsidiary – manufactured the components such as superheaters, pipes and other plant
equipment or had them manufactured. Their material properties are comprehensively
examined in the test laboratory.
38

CO 2 Capture for Industrial Processes
The carbon dioxide arising from coal combustion can be precipitated from the flue gas
and stored underground or used. CO 2 capture processes are known from their use
in the chemical industry. However, no systems to date have been able to precipitate
climate-noxious carbon dioxide in coal power plants. Power plant operators and plant
constructors across the world are intensively researching into possible CO 2 capturing
processes.
Hitachi Power Europe is, on the one hand, actively pursuing the “downstream flue gas
scrubber” (PCC – Post-Combustion Capture). This process involves the CO 2 being
scrubbed out and captured with the help of chemical solutions at the end of the power
plant operation. On the other hand, the company is researching into oxyfuel technology,
whereby coal is combusted with pure oxygen. What remains after water condensation
is practically pure CO 2 .
For the PCC process, Hitachi Power Europe has completed a CO 2 capture pilot facility
based on a gas scrubber. It was set up in cooperation with energy suppliers at a power
plant site in 2011 and is available for tests involving various chemical scrubbing
solutions. The test plant not only has the benefit of being dismountable / mountable and
deployable at various power plant sites under differing conditions, but is also not bound
to any specific chemical scrubbing agent (amine / water). The operator is free to use the
means which he finds the most suitable.
Hitachi Power Europe is developing the oxyfuel process in a technology partnership with
energy supplier Vattenfall. Here, an Hitachi oxyfuel burner has been used and tested at
the “Schwarze Pumpe” oxyfuel test plant in Brandenburg as from April 2010.
It is expected that a commercial application of CCS (carbon capture and storage) will
be undertaken in 2020.
Modular test plant
for CO 2 capture based on
the PCC process
Power Plants
Efficiency
in %
Coal Consumption
in grams
per kilowatt hour
CO ² Discharge
in grams
per kilowatt hour
worldwide
(average)
30
480
1,116
in the EU
38
379
881
modern
45
320
743
next generation
> 50
288
669
with CCS technology
~ 40
360
80–100
Source: RWE
Our Know-How 39

Stored Energy
Compressed-air energy
storage systems (right) and
underground pump energy
storage systems (below) are
just two examples of HPE
innovative solutions
1 Compressor
2 Cavern
3 Pipe Storage
4 Gas Turbine
5 Recuperator
Renewable energies – such as wind power and solar systems – make energy storage
systems a necessity as they can offset the differing levels of power feed-in to the grid.
Hitachi Power Europe develops these kinds of solutions, such as Compressed Air
Energy Storage (CAES) systems and underground pump energy storage systems.
In CAES systems, compressed air (stored in caverns or in a piping system) is used with
a gas turbine to generate power. In an underground pump energy storage system, falling
water drives the turbines which are installed several hundreds of meters under the
surface (e. g. in a disused mine)
In collaboration with parent company Hitachi, Ltd. and Japanese sister companies,
Hitachi Power Europe has the required machine technology and components (e. g.
modified gas turbines) to construct and set up these kinds of energy storage systems.
1 Storage Lake
2 Head Frame
3 Surge Shaft
4 Pump Turbine
5 Generator
6 Water Storage Gallery
40

Globally Networked
From CO 2 capture, greater efficiencies, future energy storage systems to online
simulation of a power plant via a software package – these are some of the topics that
Hitachi R & D employees touch upon in their intensive exchange of know-how – extending
across national borders – at their regular meetings. These GRDO Workshops (Global
Research & Development Organization) are just one of the many examples of how
Hitachi colleagues from Europe, Japan, South Africa and the USA are networked.
Up-to-the-minute, ongoing market observations and findings from exchanges with
customers and ministries from the various countries also find their way into the work
and exchanges of R & D staff. Thus topics for the next-but-one technology generation
are today being analyzed and prioritized on the basis of the probable market and
regulating developments. Colleagues from highly diverse divisions / companies of the
Hitachi Group work together on highly complex assignments – as is the case, for
instance, with energy storage systems – and develop collective all-in solutions. The
degree of involvement extends from Hitachi Power Systems (thermal power plant
construction and associated turbo-machinery to batteries), Hitachi Plant Technology
(system components) through to Hitachi-Mitsubishi-Hydro (HEP plants).
Sales & Proposals specialists and Service staff also take part in these kinds of crossdivisional
workshops in support of developments and refinements from their customerbased
suggestions. After all, the point of what our R & D colleagues research into today
is to be rapidly turned, if possible, into commercially successful products.
Hitachi staff from Europe,
Japan and the USA regularly
exchange their know-how
Our Know-How 41

No Lack of References
Hitachi Power Europe can look back on a long tradition in energy plant engineering.
A selection of projects from the last few years testifies to the company’s experience in
the power plant field.
Projects / Products of Hitachi Power Europe (Selection) since 2005
To photo gallery
on our home page
To the reference
configurator on our
home page
* Supply of utility steam generator, flue gas
cleaning equipment, steam turbine / generator,
civil engineering including cooling tower;
overall plant layout
** Power Train = utility steam generator, flue gas
cleaning equipment, steam turbine / generator
including balance-of-plant equipment (excluding
construction work, electrical engineering, instrumentation
& control, external coal feeding etc.)
*** in Consortium with Polimex-Mostostal
Project Customer Product Capacity
Ptolemais V
Greece
TERNA S.A. Power Train ** 1 x 660 MW
42
Kozienice
Poland
Maja / Solapur /
Raghunathpur
India
Kusile
South Africa
Medupi
South Africa
Eemshaven
Netherlands
Rotterdam
Netherlands
Wilhelmshaven
Germany
Maasvlakte
Netherlands
Moorburg
Germany
Westfalen
Germany
Datteln
Germany
Neurath F & G
Germany
Boxberg
Germany
Walsum
Germany
Gent
Belgium
Malmö
Sweden
Enea Turnkey power plant *** 1 x 1,075 MW
NTPC Utility steam generator 6 x 660 MW
ESKOM Utility steam generator 6 x 800 MW
ESKOM Utility steam generator 6 x 800 MW
RWE Flue gas cleaning 2 x 800 MW
GDF Suez Power Train ** 1 x 790 MW
GDF Suez Power Train ** 1 x 790 MW
E.ON Utility steam generator 1 x 1,100 MW
Vattenfall Utility steam generator 2 x 820 MW
RWE Flue gas cleaning 2 x 800 MW
E.ON Utility steam generator 1 x 1,100 MW
RWE Utility steam generator 2 x 1,100 MW
Vattenfall Utility steam generator 1 x 670 MW
Evonik / EVN Turnkey power plant * 1 x 750 MW
Electrabel
E.ON Sverige
Blast furnace gas
utility steam generator
Combined-cycle power plant
1 x 305 MWel
440 MWel
250 MWth
As of: May 2013

Hitachi Power Europe references – and those of its predecessor companies – in the utility
steam generator field also go back over many years.
References for Hitachi Power Europe utility steam generators, 1992 – 2008 (selection)
Project Customer Fuel type Capacity
Baoshan / Shanghai
China
Elbistan B
Turkey
Dezhou / Shandong
China
Iskenderun
Turkey
Niederaußem K
Germany
Lippendorf R & S
Germany
Boxberg Q
Germany
Yang Liu Qing
China
Majuba South
South Africa
Schkopau A & B
Germany
Altbach
Germany
Rostock
Germany
Staudinger 5
Germany
Megalopolis 4
Greece
Baoshan Iron & Steel
Co. Ltd.
Turkish Electricity Generation
& Transmission Corp.
China National Import and
Export Corp. (CNTIC)
Siemens Project Ventures /
STEAG consortium
Blast furnace gas, Coke
oven gas, Natural gas, LDO
Lignite
Bituminous coal,
Anthracite
Bituminous coal
1 x 350 MWel
4 x 360 MWel
2 x 660 MWel
2 x 660 MWel
RWE Lignite 1 x 1,012 MWel
VEAG Lignite 2 x 933 MWel
VEAG Lignite 1 x 907 MWel
CNTIC / HNPGC
Electricity Supply
Commission (ESCOM)
Bituminous coal,
Oil
Bituminous coal
2 x 330 MWel
3 x 711 MWel
3 x 660 MWel
VEBA Kraftwerke Ruhr AG Lignite 2 x 492 MWel
Neckarwerke Bituminous coal 1 x 332 MWel
KNG Kraftwerks- und
Netzgesellschaft
Bituminous coal
1 x 550 MWel
PreußenElektra Bituminous coal 1 x 550 MWel
Public Power Corporation Lignite 1 x 330 MWel
Our Know-How 43

For many years now, Hitachi Power Europe (HPE) and Hitachi Power Europe Service
(HPES) have supplied combined-cycle plants for the energy industry.
References for HPE and HPES combined-cycle plants / heat-recovery boilers (selection)
Project Customer Product Capacity
Esenyurt
Turkey
Rüsselsheim
Germany
Nowa Sarzyna
Poland
Debrecen
Hungary
Taweelah A1
UAE
Matra Repowering
Hungary
Nyíregyháza
Hungary
Vasilikos Unit 4
Cyprus
Öresundsverket
Sweden
Würzburg
Germany
Bonn
Germany
Kassel-Baunatal
Germany
Saarbrücken
Germany
Frankfurt
Germany
Doğa Enerji
Cons. Energie versorgung Opel
Enron
Debreceni Kombinált Ciklusú
Erőmű
Total Tractebel Emirates
EPC Comp.
Matra AG
E.ON Hungary
Electricity Authority of Cyprus
E.ON Gasturbiner Sverige AB
HKW Würzburg
swb Energie und Wasser
Energie- und Wasserversorgung
Bonn / Rhein-Sieg GmbH
VW Kassel GmbH
Versorgungs- und Verkehrsgesellschaft
Saarbrücken GmbH
InfraServ GmbH & Co.
Hoechst KG
Combined-cycle
plant
Combined-cycle
plant
Combined-cycle
plant
Combined-cycle
plant
Combined-cycle
plant
Combined-cycle
plant
Combined-cycle
plant
Combined-cycle
plant
Combined-cycle
plant
Combined-cycle
plant 1& 2
Heat-recovery
boiler for combined-cycle
plant
Heat-recovery
boiler for combined-cycle
plant
Heat-recovery
boiler for combined-cycle
plant
Heat-recovery
boiler for combined-cycle
plant
180 MW
110 MW
117 MW
100 MW
1360 MW
50 MW
50 MW
220 MW
447 MW
45 MW
25 MW
25 MW
45 MW
33 MW
43 MW
44

Hitachi Power Europe Service provides individual solutions and services for steam
generators and combustion systems for all conventional fuels.
References from industrial and municipal energy generation customers (selection)
Project Customer Fuel Capacity
Bremen
Germany
Derna / Tobruk
Lybia
El Tejar
Spain
Leuna
Germany
Flensburg
Germany
Obrenovac
Serbia &
Montenegro
Vienna
Austria
Cilegon-Banten
Indonesia
Kuwait
Kuwait
Maasbracht
Netherlands
Linz
Austria
Stallingborough
Great Britain
Duisburg-Hamborn
Germany
swb Erzeugung
GmbH & Co. KG
General Electricity Company
of Libya (GECOL)
Refuse-derived
fuel
Heavy oil
127 t / h steam
265 t / h steam
Oleicola El Tejar S.L. Biomass 28 t / h steam
STEAG GmbH
Residue oils,
Synthetic gases,
Refinery gases,
Natural gas
3 x 178 t / h steam
1 x 162 t / h steam
Stadtwerke Flensburg Bituminous coal 3 x 150 t / h steam
Electric Power Industry
of Serbia (EPS)
Fernwärme Wien GmbH
PT Krakatau Steel
Ministry of Electricity & Water
(MEW)
N.V. Elektriciteits-Produktiemaatschappij
Zuid-Netherland
(EPZ)
voestalpine Stahl GmbH
Millennium Inorganic Chemicals
ThyssenKrupp Steel
Lignite
Domestic /
industrial waste
Heavy oil,
natural gas
Heavy oil,
natural gas
Natural gas
Blast furnace /
natural gas
Chloric
spent gas,
natural gas
Blast furnace gas,
coke oven gas,
natural gas
920 t / h steam
2 x 55 t / h steam
350 t / h steam
975 t / h steam
1,960 t / h steam
135 t / h steam
32 t / h steam
320 t / h steam
Our Know-How 45

Inspire the Next
46

Publisher
Hitachi Power Europe GmbH
Communication
Schifferstraße 80
47059 Duisburg, Germany
pr@hitachi-power.com
Copyright Photos / Graphics
Dirk Bannert
Frank Elschner
E.ON Kraftwerke GmbH
Evonik Industries AG
Stephanie Fortmann
Hitachi Power Europe GmbH
Hitachi Power Europe Service GmbH
Friedhelm Krischer
Meeraner Dampfkesselbau GmbH
Philip Mostert
Frank Preuß
RWE Power Aktiengesellschaft
Vattenfall Europe AG
Andreas Wenzel
Layout / Overall Production
Team Stiefelhagen Werbeagentur GmbH
www.stiefelhagen.de
Our Know-How 47

© Hitachi Power Europe GmbH / 05.2013 / Printed on chlorine-free bleached paper
Hitachi Power Europe GmbH
Schifferstraße 80
47059 Duisburg, Germany
Phone +49.203.8038-0
Fax +49.203.8038-1809
infobox@hitachi-power.com
www.hitachi-power.com/en
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